System for mounting a photovoltaic module to a surface

ABSTRACT

A system for removably and adjustably mounting a device on an object is provided. The system for removably and adjustably mounting a device on an object, according to the present invention, includes an apparatus and method useful for removably and adjustably mounting one or more photovoltaic modules on an object such as a pole or roof, and includes one or more triple track rails. Also included are one or more connector brackets that are demountably attachable to the one or more triple track rails and to the object.

CROSS-REFERENCE TO RELATED APPLICATION(S)

Applicant claims priority to this continuation nonprovisional patentapplication based on the copending nonprovisional United States patentapplication filed by the same applicant and sole inventor named in thisapplication filed in the United States Patent and Trademark Office onApr. 4, 2002, application Ser. No. 10/116,384, which is acontinuation-in-part of the application filed by the same applicant andsole inventor named in this application filed on Jul. 20, 2001,application Ser. No. 09/910,655.

FIELD OF THE INVENTION

The present invention pertains generally to an apparatus and method forremovably and adjustably mounting a device on a surface. Moreparticularly, the new and useful invention claimed in this documentpertains to an system for securely, safely, yet quickly mounting one ormore photovoltaic devices onto a surface including, but not limited to,a roof. The present invention is particularly, but not exclusively,useful for removably attaching one or more photovoltaic modules, panelsand arrays to a footing, footing grid, roof, pole, or any other surface,implement or object (collectively, “object” or “objects”).

BACKGROUND OF THE INVENTION

Mounting devices to objects that are, or maybe, exposed to unpredictableand varying force vectors caused by wind, rain, and other elements ofweather present technical problems often difficult to solve. A longstanding and unsolved challenge in the solar energy industry, forexample, has been resolving how best to mount panels, modules and arraysof photovoltaic devices (collectively, “module” or “modules”) onsurfaces not only securely and safely, but also quickly. The obverseproblem also is significant to the industry, namely safely removing orreconfiguring a module that has been installed on a surface.

Solar energy radiation from the sun is capable of producing heat,causing chemical reactions, or generating electricity. The sun is anextremely powerful energy source, and solar radiation is by far thelargest source of energy received by Earth, but its intensity at theEarth's surface is comparatively low. This is partly because Earth'satmosphere and its clouds absorb or scatter as much as 54 percent of allincoming sunlight. Solar energy, however, due to technologicalimprovements in the manner of collecting the potential energy, hasbecome increasingly attractive as an energy source: it is inexhaustiblein supply, and non-polluting, both in stark contrast to fossil-fuelsources like coal, oil, and natural gas.

Sunlight reaching earth consists of approximately 50 percent visiblelight, 45 percent infrared radiation, and small amounts of ultravioletlight and other forms of electromagnetic radiation. Radiation isconvertible either into thermal energy or directly into electricity byphotovoltaic cells. In photovoltaic cells, a small electrical voltage isgenerated when light strikes the junction between a metal and asemiconductor or a junction between two different semiconductors.Although the voltage generated from a single photovoltaic cell typicallyis only a fraction of a volt, by connecting large numbers of cellstogether into panels, modules and arrays, significant electric power canbe generated. To harness radiation for direct generation of electricityusing cells collected into panels, modules and arrays, a number ofapparatus and methods for using and installing the apparatus have beendevised on which to mount modules on surfaces exposed to the radiation.The construction, installation, and use of such apparatus present anumber of unsolved problems.

A wide variety of racks, frames and associated hardware have beenproposed to mount modules on objects. Some solutions have proposedmodifications of the shape, structure and size of components of a moduleto achieve more rapid and secure mounting. Other solutions have proposedaltering the construct and design of hardware associated with installingracks, framing, and footings into a footing grid on which modules aremounted. As used in this document the term “footing grid” includes atleast a network of keepers often, but not exclusively, L-shaped andformed with at least one hole in each extension of the “L.” The keepersare connectable to a surface and are formed and shaped to permitattachment of other hardware components such as rails and frames onwhich modules may be attached.

Prior approaches suggested for mounting a module on an object includesignificant limitations and problems. A serious challenge to providing auseful apparatus and method for mounting a module on a surface arisesfrom the variety of sizes and shapes of the modules, as well as thevarying number of modules that might be required in a given situation.Another challenge that earlier suggestions did not overcome is thevariety of surfaces on which modules may or must be mounted, includingroofs, tops and sides of poles, the ground, and other locations. Earliersolutions, therefore, required construction of custom built racks to fiteach of the enumerable iterations of the sizes and shapes of modules.

Many earlier suggestions for mounting panels, modules and arrays ofphotovoltaic devices on surfaces are cumbersome, unsafe, and not easilyassembled or reconfigured. Also, none of the solutions provided anapparatus, and method for installing the apparatus, that would beuniversal. The term “universal” refers to an apparatus and method formounting modules on a wide variety of objects that not only accommodateall known shapes, configurations, and numbers of modules, but alsopermit installation top down as well as bottom up. In the industryassociated with installation of photovoltaic modules, the term “topdown” refers to mounting photovoltaic modules on structures such asframes and rails that are attached first to the footing and on thesurface on which the module is to be mounted before the module isattached to the frames or rails. For example, in the case of a module tobe mounted on a building, one or more rails first would be attached to afooting grid that earlier has been attached to the surface, in thisinstance the roof; thereafter, one or more modules would be attached tothe rails. Hardware that secures the module to the rails is attachedfrom the top, or front, of the module. The term “bottom up” refers topositioning a photovoltaic module by first attaching the module to thefooting grid and to the roof or other surface. In bottom up mounting,hardware used to secure the module to the rail is attached from thebottom or back of the module. The uniqueness of each installation, aninstaller's preferences, and the particular module all will determinewhether a top down or bottom up installation is used. Significantly,none of the currently available apparatus for mounting photovoltaicmodules to a surface allow installation both top down and bottom upusing the same rail system.

Another limitation of current approaches for mounting photovoltaicmodules to a surface is the excessive number and variety of hardwareparts and components that are required to assemble a frame or railsystem. Each module or combination of modules installed may presentdifferent shapes, sizes and configurations, thus requiring a uniquecombination of mounting hardware.

Still another unresolved problem arises from the varying shapes, sizesand configurations of modules. The arrangement of the modules on asurface such as a roof may not be dimensionally consistent with thelocation of rafters underneath the roof into which hardware must beinserted to hold the footing grid and rails.

Still another limitation of present apparatus for assembling andmounting modules on surfaces is the absence of a system and apparatusthat permits easily adjusting and readjusting of the location on a railon which the module may be positioned.

Therefore, a previously unaddressed need exists in the industry for anew and useful system for positioning a device such as a photovoltaicpanels, modules and arrays of photovoltaic devices on a surface such asa roof, pole or other surface. Particularly, there is a significant needfor a method and apparatus for mounting one or more photovoltaic modulessafely, reliably, yet quickly on a surface; removing or reconfiguringthe modules just as safely, reliably and quickly; and providing a systemthat is adjustable and expandable to allow a variety of dimensions andconfigurations.

SUMMARY OF THE INVENTION

Given the conventional solutions for solving the problems associatedwith removably and adjustably mounting a device such as a module havingany of size and shape on a wide variety of surfaces; and of mountingvarying shapes, sizes and configurations of modules on a surface such asa roof that may not be dimensionally consistent with the location ofrafters underneath the roof into which hardware must be inserted to holdthe footing grid and rails; and of reducing the number and variety ofdifferent hardware components that installers must use to installmodules, it would be desirable, and of considerable advantage, toprovide an interrelated system for quickly and safely mounting a moduleon a surface that overcomes those problems.

The present invention provides numerous advantages in connection withmounting, attaching, adjusting the configuration of one or more modules,and removing the one or more modules from a surface in a safe, reliable,yet rapid manner. At least one of the advantages of the presentinvention is that it provides an apparatus, and a method of installingthe apparatus, that allows installation both top down and bottom upusing the same rail system. The present invention also significantlyreduces the number and variety of hardware parts and components neededto assemble the apparatus. In addition, the system for removably andadjustably mounting a device on a surface provides universal hardware,permitting installation of a module on a surface either in any directionor configuration.

In addition, the present invention also allows assembly of photovoltaicmodules of any size or shape on a variety of surfaces, while insuringthat the footing grid remains securely attached to the surface. Theunique dual track rail of the present invention, in combination with thenovel clamps of the present invention, also permit ready slidableadjusting and readjusting of the location on a rail on which the modulemay be positioned. Equally significant, the present invention providesan apparatus and method for removably and adjustably mounting a devicesuch as a module on a surface which respectively are easy to use and topractice, and which are cost effective for their intended purposes.

These and other advantages are achieved in the present invention byproviding a system for removably and adjustably mounting a device on asurface that includes a rail formed with at least two tracks, and one ormore clamps for interconnecting the system. Each of the tracks includesa channel extending the length of the rail. A slot also extending thelength of the rail is formed in each channel. The slots are arranged atapproximately a right angle to each other. The unique channelconstruction helps achieve the advantages of the present invention bymaking the rail adjustable to a wide variety of modules. To adduniversality of application to the present invention, the system forremovably and adjustably mounting a device on a surface also includes atleast two different constructions of clamps for top down mounting. Oneconfiguration of the clamps is a duct with at least two opposingshoulders substantially perpendicular to one another, and is usedprimarily for mounting adjacent edges of different modules to a rail.Another configuration of the clamp is a leg having a descending memberand an ascending member extending in opposite directions. A lip, or fin,is provided on the two opposing shoulders, as well as on the ascendingmember, to provide torsional clamping power on the edges of modules. Theleg-shaped clamp is an end clamp, used primarily to mount an edge of amodule to a rail. The clamps maybe repositioned along the rail formedwith at least two tracks, making the system easily and quicklyreconfigurable.

Further optimizations in connection with the present invention isachieved by including features and elements desirable for increasing therange and variety of different applications and environments in whichthe present invention may be used. In at least one such additionaloptimization of the present invention, an apparatus and method forpositioning a module on an object includes a rail having at least threetracks (a “triple track rail” or “triple track rails”) and at least oneconnector bracket. Each triple track rail includes a proximal end, adistal end, and opposing sides. In addition, each triple track railincludes a hollow chamber extending the length of the triple track railbetween the distal end and proximal end of the triple track rail. Acavity is formed through one of the opposing sides of the rail. Theapparatus and method for positioning a module on an object also includesat least one connector bracket. The connector bracket includes a firstflange and a second flange that are positioned substantially at a rightangle to each other. The first flange is formed with a bore forinsertion of a fastener to connect the first flange to a module. Theterm “fastener” as used in this document includes any number of meansfor fastening, including without limitation a bolt, screw, clamp, dowel,rivet, and other means for fastening through a bore. The first flangealso is formed with a lip at one end. An elbow extends monolithicallyfrom the second flange at substantially a right angle to the secondflange. An end of the elbow not extending monolithically from the secondflange is insertable into the cavity formed in the hollow chamber forassisting in securely mounting the triple track rail on an object. Also,at least one semicircular groove is formed in at least one of theopposing sides of the rail. The semicircular groove is useful inassisting an installer who seeks to drill additional holes through theopposing wall to secure a mounting device in which electrical or otherlines may be secured.

The advantages and objects of such an apparatus and method forpositioning a module on an object include additional advantages inconnection with mounting, attaching, adjusting, and detaching a rail toor from one or more objects and modules, and for removing the one ormore modules from a surface and object in a safe, reliable, yet rapidmanner. At least one advantage of the present invention is an apparatus,and a method of installing the apparatus, is that it allows installationboth top down and bottom up using a rail system that includes a tripletrack rail in combination with the connector bracket of the presentinvention. The present invention also significantly reduces the numberand variety of hardware parts and components needed to assemble theapparatus and connect the apparatus to an object other than fasteners.In the vast majority of installations of a module, the connector bracketof the present invention is the only additional item of hardware neededto interconnect a rail, a module, a keeper, grid and object. Inaddition, the system provided by the present invention providesuniversal hardware, permitting installation of a module on a surface andobject either in any direction or configuration.

The present invention also allows assembly of photovoltaic modules ofany size or shape on a variety of surfaces. The unique triple track railof the present invention, in combination with the novel connectorbracket of the present invention, permit rapid installation as well asrapid adjustments and relocation of a module and a rail system. Equallysignificant, the present invention is easy to use and to practice, andis cost effective for the intended purposes.

The advantages, objects, and features of the present invention willbecome apparent to those skilled in the art when read in conjunctionwith the accompanying following description, drawing figures, andappended claims. It is clear, however, from the foregoing that theclaimed subject matter as a whole, including the structure of theapparatus, and the cooperation of the elements of the apparatus, as wellas the method for installing and using the apparatus, combine to resultin a number of unexpected advantages and utilities of the presentinvention.

The foregoing has outlined broadly the more important features of theinvention to better understand the detailed description which follows,and to better understand the contribution of the present invention tothe art. Before explaining at least one embodiment of the invention indetail, it is to be understood that the invention is not limited inapplication to the details of construction, and to the arrangements ofthe components, provided in the following description or drawingfigures. The invention is capable of other embodiments, and of beingpracticed and carried out in various ways. Also, the phraseology andterminology employed in this disclosure are for purpose of description,and should not be regarded as limiting.

As used in this document, the term “device” is not limited to thephotovoltaic environment. For example, but not by way of limitation, theterm includes any device capable of generating power, but may also be adevice capable of holding liquids, gases or admixtures of solids. Adevice may be mounted on a surface which may include the roof or wall ofa building, a pole, or any other surface. The shape of the device is notmaterial to the present invention, and may be rectangular, circular, orany other shape or configuration.

As those skilled in the art will appreciate, the conception on whichthis disclosure is based readily may be used as a basis for designingother structures, methods, and systems for carrying out the purposes ofthe present invention. The claims, therefore, include such equivalentconstructions to the extent the equivalent constructions do not departfrom the spirit and scope of the present invention. Further, theabstract associated with this disclosure is neither intended to definethe invention, which is measured by the claims, nor intended to belimiting as to the scope of the invention in any way.

The novel features of this invention, and the invention itself, both asto structure and operation, are best understood from the accompanyingdrawing, considered in connection with the accompanying description ofthe drawing, in which similar reference characters refer to similarparts, and in which:

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of the system for removably and adjustablymounting a device on a surface in an operative environment as anapparatus for removably and adjustably mounting one or more photovoltaicmodules on a surface such as a roof as shown;

FIG. 2 is a top view of a module installed on a surface;

FIG. 3 is a perspective view of a rail in accordance with the presentinvention;

FIG. 4 is an end view of a rail in accordance with the presentinvention;

FIG. 5 is a top view of a rail in accordance with the present invention;

FIG. 6 is a side view of a rail in accordance with the presentinvention;

FIG. 7 shows additional end views of a rail in accordance with thepresent invention;

FIG. 8 shows a front view of clamps in accordance with the presentinvention;

FIG. 9 shows a blown up view of the fin of a clamp as noted in FIG. 8;

FIG. 10 is a perspective view of one embodiment of the clamp;

FIG. 11 is a perspective view of yet another embodiment of the clamp;

FIG. 12 is a perspective view of the apparatus and method forpositioning a module on an object in an operative environment;

FIG. 13 is a perspective view of the triple track rail in accordancewith the present invention;

FIG. 14A is a side view of the triple track rail;

FIG. 14B is an end view of the triple track rail;

FIG. 15 is a perspective view of the connector bracket in accordancewith the present invention; and

FIG. 16 is a top partially cut away view of a module.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Briefly, the present invention provides a system for removably andadjustably mounting a device on a surface. The invention includes one ormore dual track rails and one or more unique clamps that may beinterconnected to a footing grid.

FIG. 1 illustrates the system for removably and adjustably mounting adevice on a surface in an operative environment. As shown, the presentinvention is an apparatus for removably and adjustably mounting one ormore photovoltaic modules on a surface such as a roof. Referringinitially to FIG. 1, the system for removably and adjustably mounting adevice on a surface is shown and generally designated 10. The system forremovably and adjustably mounting a device on a surface 10, according tothe present invention, includes at least one rail 12. In a preferredembodiment of the present invention, at least one rail 12 is formed ofextruded aluminum, but the material used is not a material considerationto the present invention. As shown perhaps best by cross-referencebetween FIGS. 3-7, at least one rail 12 is formed with at least twotracks 14 a,b. Both of at least two tracks 14 a,b include a channel 16a,b, perhaps best shown in FIGS. 3 and 4, extending the length of atleast one rail 12 substantially coincident with the longitudinal axis ofat least one rail 12. Each channel 16 a,b in at least two tracks 14 a,bis formed with a slot 18. Slot 18 extends the length of at least onerail 12 substantially coincident with the longitudinal axis of at leastone rail 12. In addition, in accordance with the present invention, slot18 a in channel 16 a of at least one rail 12 is formed substantially ata right angle A to slot 18 b in any other of at least two tracks 14 a,b,as shown diagrammatically in FIG. 3. As shown in FIGS. 3, 4 and 7, atleast one rail 12 is formed with a body 20. Body has a proximal end 22,a distal end 24, and a hollow chamber 26 between proximal end 22 anddistal end 24 of body 20. Hollow chamber 26 contributes to the lightweight yet structural rigidity of at least one rail, and therefore toits ease of handling during installation of system for removably andadjustably mounting a device on a surface 10. In a preferred embodimentof the present invention, at least one rail 12 also is formed withopposing sides 28 a,b and opposing shoulders 30 a,b.

As further shown in FIG. 3, body 20 includes channel 16 b formed inopposing side 28 b for slidably engaging the rail on hardware describedbelow. Channel 16 b is formed with slot 18 b extending along thelongitudinal axis of at least one rail 12. In a preferred embodiment ofthe present invention, slot 18 a also includes opposing jaws 32 a,bmonolithically protruding from slot 18 substantially along thelongitudinal axis of the first channel 16. Body 20 further includeschannel 16 a. Channel 16 a is formed in opposing shoulder 30 a as shownin FIGS. 3 and 4. Channel 16 a also contributes, in combination withchannel 16 b, to making at least one rail 12 slidably engageable withthe one or more footings 36. As will be apparent to a person skilled inthe art, channel 16 a and channel 16 b enable at least one rail 12 to beslidable engageable with one or more footings 36.

As also shown by cross-reference among FIGS. 8-11, a system forremovably and adjustably mounting a device on a surface 10 also includesone or more clamps 34 a,b. As shown best by reference to FIGS. 8 and 10,one or more clamps 34 is formed as a duct 42. Duct 42 includes at leasttwo opposing flanges 44 a,b. Opposing flanges 44 a,b of one or moreclamps 34 a,b are substantially perpendicular to one another. One ormore clamps 34 may also be described as formed with a plate 46 andmonolithic opposing side walls 48 extending substantially in the samedirection at substantially right angles B from plate 46. Opposing sidewalls 48 include a lower inner edge 50 and an upper face 52. A fin 54extends from upper face 52 substantially along the longitudinal axis ofone or more clamps 34 a,b. One or more clamps 34 a,b also includes leastone hole 56 through plate 46 for securing one or more clamps 34 a,b asdescribed below.

In an alternative embodiment of one or more clamps 34, one or moreclamps 34 is formed with a leg 58 having a base 60 as shown best in FIG.11. From base 60 of leg 58 a descending member 62 monolithically extendsfrom base 60. In addition, from base 60 of leg 58 an ascending member 64monolithically extends from base 60 in a direction substantiallyopposite the direction of descending member 62. As also shown in Figure,one or more clamps 34 include means 66 for connecting base 68 to atleast one rail 12. One or more clamps 34 also includes means 70 forvariably positioning one or more clamps 34 in channel 16 of at least onerail 12.

FIG. 1 also shows a device 68 that may be mounted on surface 40 usingthe present invention. In a preferred embodiment of the presentinvention, device 68 is a photovoltaic module 68′, also shown in FIG. 2.Photovoltaic module 68′ is formed with an edge 72. In a photovoltaicenvironment for application of the present invention, edge 72 holds oneor more photovoltaic panels 74. As also shown best in FIGS. 1 and 2,footing grid 38 includes one or more footings 36. In combination, theone or more footings 36 compose a network of keepers 76. In thepreferred embodiment of the present invention, each of the network ofkeepers 76 is L-shaped and constructed of metal. Neither the shape normaterial of the keepers 76 is a material limitation of the presentinvention. Each of keepers 76 may be fastened to surface 40. If surface40 is a roof of a building, keepers 76 may be attached to surface 40 byinserting lag bolts (not shown) through keepers 76 into rafters 78beneath surface 40. Once installed, keepers 76 form a grid, as shown inFIG. 1, on which at least one rail 12 of the present invention isremovably connectable.

Using the principal embodiment of the present invention, in operationone or more clamps 34 a,b are variably positionable not only on at leastone rail 12, but also on footing grid 38 for demountably securing module68′ to footing grid 38, as shown by reference to FIG. 1. As shown inFIG. 9, a preferred embodiment of fin 54 a,b includes a serrated surface55 that grips edge 72 of module 68′ with significant torsional rigidity,but because of the use of conventional hardware for attaching one ormore clamps 34 a,b to edge 72 of module 68′, one or more clamps 34 arequickly and safely repositionable. As further shown by cross-referencebetween FIGS. 1 and 4 channel 16 a, during installation, maybe slidablyengaged with at least one rail 12 and to footing grid 38. As shown inFIG. 4, slot 18 includes opposing jaws 32 monolithically protruding fromslot 18 substantially along the longitudinal axis of channel 16 a. Jaws32 contribute to making one or more clamps 34 a,b slidable and removablyengageable, and therefore allow the present invention to be not onlymounted, but reconfigured on surface 40. Channel 16 b also contributes,in combination with first channel 16 a, to making at least one rail 12slidably engageable, and repositionable, with one or more clamps 34 a,b.As will be apparent to a person skilled in the art, channel 16 a andchannel 16 b enable at least one rail 12 to be slidable engageable withnot only one or more clamps 34 a,b, but also with footers 36 comprisingfooting grid 38.

While the system for removably and adjustably mounting a device on asurface 10 as shown in drawing FIGS. 1 through 11 is one embodiment ofthe present invention, it is only one such embodiment of the invention,is not intended to be exclusive, and is not a limitation of the presentinvention. The particular a system for removably and adjustably mountinga device on a surface as shown and disclosed in detail in thisinstrument is fully capable of obtaining the objects and providing theadvantages stated, but this disclosure is merely illustrative of thepresently preferred embodiments of the invention, and no limitations areintended in connection with the details of construction, design orcomposition other than as provided and described in the appended claims.

Further optimizations in connection with the present invention areachieved by including features and elements desirable for increasing therange and variety of different applications and environments in whichthe present invention may be used. In at least one such additionaloptimization of the present invention, an apparatus and method forpositioning a module on an object is provided. The present inventionincludes one or more rails having at least three rails (a “triple trackrail” or “triple track rails”) used in combination with at least oneconnector bracket.

FIG. 12 illustrates the apparatus for positioning a module on an objectin an operative environment. As shown, the present invention includes anapparatus for removably and adjustably mounting one or more photovoltaicmodules on an object such as a pole or roof. Referring initially to FIG.12, the apparatus for positioning a module on an object is shown andgenerally designated 100. The apparatus 100 for positioning a module 68′on an object, according to the present invention, includes at least onerail 102. In a preferred embodiment of the present invention, at leastone rail 102 is formed of extruded aluminum, but neither the materialsused nor the extrusion method of manufacture is material to the presentinvention.

As shown perhaps best by cross-reference among FIGS. 13, 14A and 14B, atleast one rail 102 is formed with at least three tracks 104 a,b,c. Twoof at least three tracks 104 a,b,c include a channel 106 a,b. Forillustrative purposes, as best shown by cross-reference among FIGS. 13,14A and 14B, two of the at least three tracks 104 a,b,c are shown withchannels 106 a,b extending the length of at least one rail 102substantially parallel to the longitudinal axis of at least one rail102. Each channel 106 a,b in at least two tracks 104 a,b is formed witha slot 108 that for illustrative purposes are shown as slots 108 a,b.Slot 108 a,b extends the length of at least one rail 102 substantiallyparallel to the longitudinal axis of at least one rail 102. In addition,in accordance with the present invention, slot 108 a in channel 106 a ofat least one rail 102 is formed substantially at a right angle A to slot108 b as shown diagrammatically in FIG. 13.

As shown in FIGS. 13, 14A and 14B, at least one rail 102 also is formedwith a body 110. Body 110 has a proximal end 112, a distal end 114 asbest shown in FIG. 13, and a hollow chamber 116 between proximal end 112and distal end 114 of body 110 as best shown in FIG. 14B. Hollow chamber116 contributes to the light weight yet structural rigidity of at leastone rail, and therefore to its ease of handling during installation ofapparatus while positioning a module 68′ on an object. In a preferredembodiment of the present invention, as best shown in FIGS. 13 and 14B,at least one rail 102 also is formed with opposing sides 118 a,b andopposing shoulders 120 a,b. In operation, as further shown in FIGS. 14Band 15, tracks 104 a,b permit at least one rail 102 to be slidablyengageable on hardware described below.

In a preferred embodiment of the present invention, as shown bycross-reference between FIGS. 13 and 14B, slot 108 a,b also includesopposing jaws 122 a,b monolithically protruding from slot 108 a,bsubstantially along the longitudinal axis of channel 106 a,b. Channel106 a is formed in opposing shoulder 120 a as shown in FIG. 14B. Channel106 a also contributes, in combination with channel 106 b, to making atleast one rail 102 slidably engageable with the one or more footers 36.

Apparatus for positioning a module on an object 100, as shown bycross-reference between FIGS. 13 and 14B, also includes a cavity 124formed in body 110 of at least one rail 102. Cavity 124 is formedthrough at least one opposing side 118 a,b, and for illustrativepurposes is shown in FIG. 14B as being formed through at least oneopposing side 118 b. As also shown in FIG. 14B, an opening 126 is formedin opposing side 118 b. Opening 126 in opposing side 118 b is defined bya boss 128 also formed in opposing side 118 b as well as by a shelf 130.In a preferred embodiment of the present invention, shelf 130 is formedmonolithically from edge 132 in opposing side 118 b that is oppositeboss 128. Shelf 130 also extends monolithically into hollow chamber 116to form a partition 134 that is best shown in FIG. 14B. Partition 134merges monolithically into beam 136 in slot 108 a, as best shown in FIG.14B.

In addition, as also shown in FIG. 14B, a boom 138 extends throughhollow chamber 116 between opposing sides 118 a,b of rail 102. Inoperation, boom 138 resists compressive and similar forces appliedagainst rail 102, thus enhancing the rigidity and longevity of apparatusfor positioning a module on an object 100 when installed. Also in apreferred embodiment of the present invention, hollow chamber 116 isformed with a substantially semicircular passage 140, as best shown inFIGS. 13 and 14B. In operation, use of semicircular passage 140 insteadof, for example, a passage having a rectangular shaped cross-section,also contributes to resisting compressive and other forces on apparatusfor positioning a module on an object 100 after installation andmounting of rail 102 on module 68′. In a preferred embodiment of thepresent invention, at least one semicircular groove 142 is formed in atleast one of the opposing sides 118 a,b as shown in FIG. 13, forassisting an installer in drilling one or more additional holes (notshown) through opposing sides 118 a,b for securing a mounting device(not shown) in which electrical or other lines may be secured.

Also included in the present invention of an apparatus for positioning amodule on an object 100 are one or more connector brackets 144, as shownby cross-reference between FIGS. 14B and 15. One or more connectorbrackets 144 is formed to be demountably attachable to at least one rail102 and to device 68 or module 68′. To achieve that object, one or moreconnector brackets 144 is monolithically formed with a first flange 146and a second flange 148 substantially at a right angle as showndiagrammatically as Angle B in FIG. 15. First flange 146 is formed witha lip 150. In addition, first flange 146 is formed with a bore 152. Inoperation, bore 152 is provided for insertion of a fastener 153 throughbore 152 to secure connector bracket 144 to device 68 or module 68′. Ina preferred embodiment of the present invention, one or more connectorbrackets 144 further comprises an elbow 154. Elbow 154 is substantiallyL-shaped, and extends monolithically at substantially a right angle fromsecond flange 148 as shown diagrammatically as Angle C in FIG. 15. Elbow154 is shaped and configured for detachable engagement with cavity 124formed in hollow chamber 116 of body 110. As shown best in FIG. 14B,elbow 154 is engageable with boss 128 as well as beam 136.

In operation, as will be evident to one skilled in the art, the uniquecombination of one or more connector brackets 144, cavity 124, and threetracks 104 formed in at least one rail 102 (collectively, the “combinedcomponents”) permits installation of apparatus for positioning a moduleon an object 100 in a wide variety of alternative ways. For example, asshown in FIG. 16, module 68′ is typically formed with a collector side156 and a back side 158. The term “collector side” refers generally tothat side of module 68′ that collects solar energy radiation from thesun. The term “back side” refers generally to that side of module 68′that does not collect solar energy radiation from the sun. The combinedcomponents permit an installer to select module 68′ having at leastcollector side 156 and back side 158, constructed with at least twoopposing edges 160 a,b having a plurality of holes 162 a,b. The combinedcomponents permit an installer to position module 68′ collector side 156down, mount at least one rail 102 on the back side 158 of module 68′,and reposition the combined components collector side 156 up to installthe combined components on the object 68. Alternatively, the combinedcomponents allow an installer to install the components either top downor bottom up.

1. A system for removably and adjustably mounting a photovoltaic moduleor flat panel to a surface, comprising: a rail formed with two or moretracks, wherein the rail is formed of extruded aluminum and furthercomprises a cavity substantially parallel to the longitudinal axis ofthe rail; and means for connecting the rail to the said photovoltaicmodule or flat panel, wherein the rail is formed with a body having aproximal end, a distal end, opposing sides, and a hollow chamberextending the length of the rail substantially parallel to thelongitudinal axis of the rail, and further wherein the cavity is formedin the side of the hollow chamber through one of the opposing sides, andfurther wherein the means for connecting the rail to said photovoltaicmodule or flat panel is one or more connector brackets demountablyattachable to the rail and to the object, and monolithically formed witha first flange and a second flange substantially at a right angle,wherein the first flange is formed with a lip.
 2. A system for removablyand adjustably mounting a photovoltaic module or flat panel on a surfaceas recited in claim 1, wherein the first flange is formed with a bore.3. A system for removably and adjustably mounting a photovoltaic moduleor flat panel on a surface as recited in claim 1, wherein the one ormore connector brackets are removably engageable with said cavity formedin the side of said hollow chamber.